Cast concrete paver block

ABSTRACT

Precast concrete paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, the tapered joint projection on each block enters the joint recess on the other block. The taper on the projections move the blocks to align the block surfaces. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.

TECHNICAL FIELD

[0003] The invention relates to precast concrete products and moreparticularly to a precast concrete paver block.

BACKGROUND OF THE INVENTION

[0004] Precast concrete paver blocks are used for many applications,such as patios, driveways, sidewalks and courtyards. In the past,concrete paver blocks have generally been relative small, frequentlyfrom about the size of a brick up to about 2 feet square (about 61 cmsquare). In some applications, thin, decorative pavers are used asoverlays on concrete foundations. Large pavers have not been available.One problem with larger paver blocks is to maintain a flat surface wherethe blocks abut. It is difficult to provide a flat foundation for theblocks and to prevent shifting of the blocks with ground movement, forexample, due to frost or heavy rainfall.

BRIEF SUMMARY OF THE INVENTION

[0005] The invention is directed to large precast concrete paver blocksof a type suitable for constructing driveways, sidewalks, patios,courtyards, boat ramps, and the like. Optionally, the exposed surfacesof the blocks are textured and, optionally, colored, to simulate naturalstone. The paver blocks are provided with interlocking edge joints sothat abutting edges of adjacent paver blocks align when the blocks areinstalled and are maintained in alignment. At each edge joint, eachblock includes a tapered projection and a recess. When edges of twoblocks are moved to abut each other, each tapered projection on eachblock enters a recess on the other block. The taper on the projectionsmove the blocks into alignment. Preferably, there are at least two edgejoints on each block edge which will abut another block edge. The edgesof the blocks are angled or relieved below the joints to ensure a tightfit at the top of the paver blocks.

[0006] Accordingly, it is an object of the invention to provide castconcrete paver blocks with edges which interlock for initially aligningand for maintaining alignment of abutting block edges.

[0007] Other objects and advantages of the invention will becomeapparent from the following detailed description of the invention andthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a fragmentary perspective view showing an exemplarylayout for a driveway, a sidewalk, steps and a patio constructed withcast concrete paver blocks according to the invention;

[0009]FIG. 2 is a top plan view of a rectangular paver block accordingto the invention;

[0010]FIG. 3 is a top plan view of a corner paver block according to theinvention;

[0011]FIG. 4 is a top plan view of a square paver block according to theinvention;

[0012]FIG. 5 is a top plan view of a triangular paver block according tothe invention;

[0013]FIG. 6 is an enlarged fragmentary cross sectional view showingdetails of the connection between abutting edges of two paver blocksaccording to the invention;

[0014]FIG. 7 is a fragmentary side view of abutting edges of two paverblocks which have a slight angle between the blocks; and

[0015]FIG. 8 is a fragmentary cross sectional view showing details ofone joint on one of the paver blocks.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to FIG. 1, an exemplary layout 10 is shown for aresidential application including a driveway 11, a sidewalk 12, steps 13and a patio 14 made from different types of cast paver blocks. Theillustrated layout 10 is formed from four different shaped blocks,consisting of rectangular paver blocks 15, corner paver blocks 16,square paver blocks 17 and triangular paver blocks 18. Although the fourillustrated block shapes will work for most applications, it will beappreciated that other block shapes also may be made to meet specificapplication requirements.

[0017] The blocks 15-18 are cast from concrete and, preferably, arereinforced with steel mesh or with rebar rods to provide the strengthrequired for the application. For example, greater reinforcement will beneeded for paver blocks used in a driveway 11 which must support theweight of heavy vehicles, than for paver blocks used in a patio 14 or inportions of a sidewalk 12 which do not cross a driveway. The blocks15-18 are cast to a desired thickness, such as 4 inches (10.2 cm). Inorder to provide a pleasing appearance, the exposed top surfaces and anyexposed edges of the blocks 15-18 may be textured, for example, tosimulate natural stone. The block surfaces also may be stained orotherwise colored to more closely simulate stone using techniques whichare well known in the art or to provide a desired appearance.

[0018] According to the invention, the sides of the blocks which abutthe sides of other blocks are provided with one or more joints 19 whichengage complimentary joints on the other blocks. The joints 19 arespaced on each block side for engaging the complimentary joint 19 on anabutting block side. FIG. 2 shows the rectangular block 15 as having twoshort sides 20 and 21, each having two joints 19, and as having two longsides 22 and 23, each having three joints 19. The rectangular block 15may have, for example, a width of 4 feet (122 cm) and a length of 6 feet(183 cm).

[0019]FIG. 3 shows details of the corner block 16. The block 16 issubstantially trapezoidal in shape having a side 24 which is either 4feet (122 cm) or 6 feet (183 cm) long, two angled sides 25 and 26 whichare 4 feet (122 cm) long and, for example, form an angle of 30° to eachother, and a side 27 which is shorter than the side 24. In order to keepthe width of the block at 4 feet or the width of the rectangular blocks15, ends 28 of the side 24 are slightly angled. By arranging the sides25 and 26 at an angle of 30°, three corner blocks 16 can be used to forma 90° bend. If the sides 25 and 26 were angled at 45°, two blocks 16would be used to form a 90° bend. The block 16 is intended to have thesides 25 and 26 abut sides of other blocks 15-18. Thus, the sides 25 and26 are each provided with two joints 19. The center portion of the side24 (without the ends 28) may be of the same length as the side 27, forexample, either 4 feet (122 cm) or 6 feet (183 cm). This will allowabutting a block to the center portion of the side 24.

[0020]FIG. 4 shows the square block 17, which has four sides 29-32, eachof which is 4 feet (122 cm) long. Each side 29-32 has two joints 19.

[0021]FIG. 5 shows the triangular block 18, which has two adjacent 4feet (122 cm) long sides 33 and 34 which form a 90° angle and a longside 35. Each of the sides 33 and 34 has two joints 19 for engagingjoints on the other blocks.

[0022]FIGS. 6-8 show details of a construction for the joints 19. Eachjoint 19 extends along an edge 38 of the block parallel to a top surface39 of the block. Each joint 19 consists of a projecting rib 40 and of agroove 41 sized and shaped to receive a projecting rib 40 from a joint19 on an abutting block. Preferably, the rib 40 is triangular or wedgeshaped in cross section with sides 42 and ends 43 which taper to an apex44. Thus, the sides 42 are trapezoidal shaped and the ends 43 aretriangular shaped. The groove 41 has complementary tapered sides andends which are sized to receive the rib 40. Consequently, when twojoints 19 are moved into position where the adjacent sides 38 abut, asshown in FIG. 6, the top surfaces 39 of the adjacent blocks are movedinto alignment when the rib 40 is moved into the groove 41. Tapering theribs 40 in two directions facilitates alignment of the blocks when theyare positioned to form a desired layout. In the drawings, the rib 40 andthe groove 41 for each joint 19 are shown as being aligned and adjacenteach other. It will be appreciated that the rig 40 and the groove 41 maybe spaced from each other, so long as they have the same spacing fromthe top surface 39.

[0023] A lower portion 45 of the edge 38 on each block may be angledslightly inwardly from the joint 19 to a bottom 46 of the block to forman angle between the lower portion 45 and the bottom 46 greater than90°. Optionally, a chamfer may be provided between the lower portion 45and the bottom 46 to eliminate sharp edges which may be subject toimpact damage when installing the paver block. The angled lower portion45 serves two functions. First, it allows a relief area for any dirt orother foundation material which may be trapped between the abuttingedges. Second, it allows two adjacent blocks to be slightly angledrelative to each other when the ground on which the blocks are placed isnot level, while maintaining a tighter fit at the top of the paverblock.

[0024] The joints 19 are formed to have the same configuration on eachside of the block which will abut a side of another block. Thus, whenlooking at an elevational view of any block side having a joint 19, therib 40 will be on the left side of the joint 19 and the recess 41 willbe to the right of the rib 40. As a consequence, when any two sides aremoved into an abutting arrangement, the two joints are complementary andeach rib 40 will align with a recess 41. Alternately, all of the joints19 can be made with the ribs 40 on the right and the recesses 41 on theleft.

[0025] The joints 19 may be omitted from edges of the cast paver blockswhich will not abut an adjacent paver block, especially any of thesesides which may be visible after the blocks are installed. These edgesmay be textured with a pattern and colored similar to the exposed topsurface of the block.

[0026] It will be appreciated that various modifications and changes maybe made to the above described preferred embodiment of a cast concretepaver block without departing from the scope of the following claims.Although a preferred construction for the joints 19 has been described,it will be appreciated that other configurations also may be used toachieve the same results. For example, the ribs 40 can be replaced withround or oval knobs and the recesses 41 can be configured to receive theknobs. Also, the number of joints 19 on each side of the paver blocksmay be changed to meet the needs for any particular application.

[0027] The block dimensions provided herein are intended to beexemplary. It will be appreciated that the block dimensions can bemodified to meet local building codes and conventional sized in thecommunity in which the blocks are used. However, the invention isparticularly useful for paver blocks having a minimum dimension of atleast 3 feet (91 cm) for providing larger hard surfaces.

1. A cast concrete paver block having a top surface, a bottom, and atleast three side edges, and at least two joints on at least one of saidside edges, wherein each of said joints is adapted to engage acomplementary joint on an edge of another paver block, and wherein eachjoint includes a portion projecting form said at least one side edge anda recess in said at least one side edge, and wherein said projection istapered to facilitate alignment with a complementary joint on an edge ofanother paver block when said block edges are moved together.
 2. A castconcrete paver block, as set forth in claim 1, and wherein said jointson said at least one edge are spaced a predetermined distance below thetop surface, and wherein said at least one side edge below said jointsis angled towards said bottom at an angle greater than 90°.
 3. A castconcrete paver block, as set forth in claim 2, and further including achamfer between said at least one side edge and said bottom.
 4. A castconcrete paver block, as set forth in claim 2, and wherein for eachjoint, said projection is elongated extending along a line substantiallyparallel to said top surface, and wherein said recess is at least aslong as said projection and extends along said line substantiallyparallel to said top surface.
 5. A cast concrete paver block, as setforth in claim 4, and wherein for each joint, said projection has anupper surface and a lower surface angled towards an apex, and opposingends angled towards said apex, whereby said upper and lower surfaces aretrapezoidal shaped and said opposing ends are triangular.
 6. A castconcrete paver block, as set forth in claim 1, and wherein for eachjoint, said projection is elongated extending along a line substantiallyparallel to said top surface, and wherein said recess is at least aslong as said projection and extends along said line substantiallyparallel to said top surface.
 7. A cast concrete paver block, as setforth in claim 6, and wherein for each joint, said projection has anupper surface and a lower surface angled towards an apex, and opposingends angled towards said apex, whereby said upper and lower surfaces aretrapezoidal shaped and said opposing ends are triangular.
 8. A castconcrete paver block, as set forth in claim 6, and wherein said blockhas a predetermined uniform spacing between each two adjacent joints onsaid at least one side edge.
 9. A cast concrete paver block, as setforth in claim 1, and wherein at least said top surface is textured tosimulate natural stone.
 10. A cast concrete paver block, as set forth inclaim 9, and wherein side edges of said block which do not includejoints are textured to simulate natural stone.
 11. A cast concrete paverblock having a top surface, a bottom, and six side edges, first andsecond of said side edges extending parallel to each other, third andfourth of said side edges joining opposite ends of said first side edgeand each extending at angles of at least 15° to said first side edge,and fifth and sixth of said side edges connecting between opposite endsof said second side edge and ends of said third and forth side edges.12. A cast concrete paver block, as set forth in claim 11, and whereinsaid first and second side edges are of the same length and at least aslong as said third and forth side edges.